LEAN APPROACH A CASE STUDY

Jai Parvati Forge Ltd Continual Improvement Program Drives More Than INR 600,000 in Savings A QS
Client Case Study With over 20 years experience, JPF is a leader in automotive aftermarket parts.
Headquartered Derabassi ( Punjab), and employing over 1000 people, JPF group which Includes Forging,
Machining units provides a full range of superior quality replacement parts to keep both foreign and
domestic vehicles in top working order. JPF services all of these stores and distributors from their Baddi
( HIMACHAL PRADESH) Manufacturing, a 360,000 square foot facility that operates two shifts, six days
a week, and houses over 40,000 unique part numbers. Taking advantage of a MSME , AND NATIONAL
PRODUCTIVITY COUNCIL , Jai Parvati Forge Group began working with Ankur Dhir, QS Lean
Manufacturing consultant Empannelled BY NPC , in 2012 to learn and apply lean thinking to its
distribution operations. Ron provided introductory lean training followed by value stream mapping,
5S/Workplace Organization, Kanban/Pull Systems, Poka-Yoke (mistakeproofing), and Problem-solving
training and practice. In the last few months Ankur has been helping JPF develop internal training
capabilities through a Lean Train-the-Trainer effort. Recently, JPF took stock of some of the benefits they
have received from their continuous improvement efforts.

Achievements to date include:

Shipping productivity increased from 96 lines/labor hour to 135 lines/labor hour, a 40% increase,
saving INR 1,20,000
Travel in the Reclamation Process has been reduced by 85%, for a savings of $19,525
Boxes have been replaced by reusable totes, saving INR 1,80,000
Pallet foundation organization resulted in a 15% productivity improvement and a INR 100,000 savings
Addition of an open top wood dumpster saved INR 50,465/year
In-store inventory availability rate has increased from 95% to 97% purchases
A kanban system was set up for pallets for a cost reduction of $350

It is really exciting to see the changes happening at JPF, said QSs Ankur Dhir. Recently, Mr.S.S Bhullar ,
the General Manager, has really accelerated lean efforts in his areas of responsibility and collectively JPF
has saved over INR600,000 from improvement efforts year over year. As a result of their ideas,

employees are benefitting from working in better processes and customers are being serviced more
efficiently. And the best part is, I think they can accomplish much more given the enthusiasm and
support that is now in place for lean.
Mr. Sushil Chandel JPF Dispatch Manager, stated, Without this training we would never have
exceeded our yearly productivity improvement target of 10% per year in the shipping department for
the past two years. We could not have done it without involving all of our Team Members.

For More details Contact Ankur Dhir dhir.ankur@gmail.com